Detecting an unsecured state of a mandrel

ABSTRACT

A method for analyzing a mandrel ( 108 ) operation in an imaging device ( 100 ) includes installing the mandrel into the imaging device; securing the mandrel between a head stock ( 144 ) and a tail stock ( 104 ); attaching a first encoder ( 212 ) to the head stock and a second encoder ( 208 ) to the tail stock; rotating the mandrel; reading signals from first encoder; reading signals from second encoder; comparing the first results and the second results; and if the first results do not match with the second results stopping the imaging device.

CROSS REFERENCE TO RELATED APPLICATIONS

Reference is made to commonly-assigned copending U.S. patent applicationSer. No. ______ (Attorney Docket No. K000869US01/NAB), filed herewith,entitled DETECTING AN UNSECURED STATE OF A MANDREL, by Olpak et al.; andU.S. patent application Ser. No. 13/279,370, filed Oct. 24, 2011,entitled SAFETY COMPONENT IN A PROGRAMABLE COMPONENTS CHAIN, by ArieGez; the disclosures of which are incorporated herein.

FIELD OF THE INVENTION

This invention relates to a laser imaging device for flexographicsleeves installed on a detachable mandrel and more specifically todetecting an unsecured mandrel in an imaging device.

BACKGROUND OF THE INVENTION

In many types of printing, particularly flexographic printing, offsetprinting and screen printing, there is an advantage in using seamlesssleeves as printing elements instead of plates wrapped around printingcylinders. Seamless sleeves allow printing of continuous patterns. Theuse of seamless sleeves allows printing presses to operate in a smoothermanner. Before a sleeve can be mounted on a printing press it has to beimaged and processed, although some materials are available today whichdo not require processing. The printing sleeves 116 are imaged on laserimaging device 100 as is shown in FIG. 1.

Such machines have a mandrel 108 on which a printing sleeve 116 ismounted directly. The mandrel 108 is secured in the imaging device 100at two ends by a tail stock 104 and a head stock 144. A laser imaginghead 120 is adapted to travel along the longitudinal axis of theprinting sleeve 116 on imaging head tracks 124, controlled by lead screw128.

Printing sleeve 116 is loaded over the mandrel 108. The printing sleeve116 may be a thin-walled metal or composite cylindrical tube with mediaapplied to the outer surface. The mandrel 108 may be provided with anumber of air holes 112 in its surface through which air can be forced.This air flow creates an air bearing over mandrel 108 and permitsprinting sleeve 116 to be floated on a cushion of air onto the mandrel108, the air expanding printing sleeve 116 to enable easy loading andpositioning. The air is supplied by air source 140 through air hose 136.Air hose 136 is fixed to air source 140 on one side and to air inlet 132on mandrel 108 on the other side of the air hose 136. When the supply offorced air is discontinued, printing sleeve 116 contracts to form atight fit with mandrel 108.

Mandrel 108 is heavy and rotates at high speed. It is important,therefore, that the mandrel be securely attached at both ends. Detectingwhether the mandrel 108 is securely fastened to both the trail stock 104and head stock 144 is necessary to prevent problems during normaloperation of imaging device 100.

SUMMARY OF THE INVENTION

Briefly, according to one aspect of the present invention a method foranalyzing a mandrel operation in an imaging device includes installingthe mandrel into the imaging device; securing the mandrel between a headstock and a tail stock; attaching a first encoder to the head stock anda second encoder to the tail stock; rotating the mandrel; readingsignals from first encoder; reading signals from second encoder;comparing the first results and the second results; and if the firstresults do not match with the second results stopping the imagingdevice.

The invention and its objects and advantages will become more apparentin the detailed description of the preferred embodiment presented below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic showing a prior art laser processing system with asleeve mounted on a mandrel adaptor using air supply; and

FIG. 2 is a schematic showing the mandrel setup between the head stockand the tail stock and encoder logic to detect whether the mandrel issecured between tail and head stock.

DETAILED DESCRIPTION OF THE INVENTION

In the following detailed description, numerous specific details are setforth in order to provide a thorough understanding of the disclosure.However, it will be understood by those skilled in the art that theteachings of the present disclosure may be practiced without thesespecific details. In other instances, well-known methods, procedures,components and circuits have not been described in detail so as not toobscure the teachings of the present disclosure.

Mandrel 108 may spin in the imaging device 100 during imaging at speedssuch as 1600 revolutions per minute (RPM). Since mandrel 108 isdetachable it is necessary to assure it is properly locked in positionwith mandrel lock 220 as shown in FIG. 2. A mandrel 108 if detached fromits secure position may cause injury, or in cases where the mandrel isnot perfectly positioned, imaging quality artifacts may show on theprinted material. The mandrel 108 is detachable, the mandrel designincludes a screw attachment connected to spindle assembly 144 (headstock) from one side and to a “stinger” 104 connected (tail stock) onthe other side.

The mandrel 108 may slightly slip from its operational positionespecially when mandrel 108 rotates at high speeds. In this case thecruise rotation speed may be right but the mandrel 108 image trackingmechanism will lose position. The position of mandrel 108 in the imagingdevice 100 is detected by encoders on both sides of the mandrel. Encoder208 is attached to the tail stock 104 and monitors the mandrel 108revolution next to the tail stock 104. Encoder 212 is attached to headstock 144 and monitors mandrel movement next to head stock.

The rotational speed of mandrel 108 on both ends of the mandrel ismeasured at the head stock 144 and tail stock 104. A comparison is madebetween the measurements at the tail and head stocks. Whether themandrel is perfectly secured between the two ends 104 and 144, orwhether mandrel 108 is not well secured is determined by a speeddifferential between the encoders.

Two encoders are used in this configuration. Encoder 212 on spindle(head stock) 144, and encoder 208 on tail stock 104. The encoders willconstantly measure the signals and pulses which are generated at each ofthe ends during mandrel 108 rotation. The results of the encoders(number of pulses per full rotation) can also determine the level andseverity of abnormal position of mandrel 108 in imaging device 100.

Head stock 144 is driven by a belt 216 which is connected to drum motor204. A third encoder, drum motor encoder 232 is attached to motor 204. Acomparison between the results of encoder 232 and 212 is made duringoperation of the imaging device 100. The comparison may help determinewhether belt 216 is properly positioned between the drum motor 204 andspindle 144 (head stock).

Analyzer 224 is configured to read results acquired by encoders 208,212, and 232. Input data from tail stock is received by analyzer 224 viainput line 236 from tail stock, input data from head stock is receivedvia input line 240 from head stock, and input line from drum motor isreceived via input line 244 from the drum motor.

The analyzer 224 will process the results acquired from all encoders(208, 212, 232), each encoder is adapted to handle input data in speedsof hundred thousand pulses per minute. In one embodiment, when anabnormal situation is encountered in the operation of the mandrel 108,an alarm 260 alerts an operator. The operator makes a decision whetherto stop the operation of the imaging device or to reduce the spinningspeed of the mandrel. Example of abnormal operation of the mandrel mayinclude, mandrel slippage, mandrel vibration during spinning, or theimaging device being started without an installed mandrel. In anotherembodiment, the process may be automated.

Slippage of the mandrel can be detected in various slippage degrees. Thedegree of slippage can be derived dependent on the number of encoderslots 256 in tail stock encoder 208. In the case when a hazardous stateof the mandrel 108 is detected by analyzer 224, the analyzer will sendinstructions to motor driver 228 via output lines 248. The instructionmay be to stop or reduce speed of drum motor 204. In this case motordriver 228 will send a corresponding command (to stop or reduce speed)to drum motor 204 via output lines 252.

The invention has been described in detail with particular reference tocertain preferred embodiments thereof, but it will be understood thatvariations and modifications can be effected within the scope of theinvention.

PARTS LIST

-   100 imaging device-   104 tail stock-   108 mandrel-   112 air holes-   116 printing sleeve-   120 imaging head-   124 imaging head tracks-   128 lead screw-   132 air inlet into mandrel-   136 air hose-   140 air source-   144 head stock (spindle)-   204 drum motor-   208 tail stock encoder-   212 head stock (drum) encoder-   216 belt-   220 mandrel lock-   224 analyzer-   228 motor driver-   232 drum motor encoder-   236 input line from tail stock encoder-   240 input line from head stock-   244 input line from drum motor encoder-   248 output line from analyzer to motor driver-   252 output line from motor driver to drum motor-   256 encoder slots-   260 alarm

1. A method for analyzing a mandrel operation in an imaging devicecomprising: installing the mandrel into the imaging device; securing themandrel between a head stock and a tail stock; attaching a first encoderto the head stock and a second encoder to the tail stock; rotating themandrel; reading signals from first encoder; reading signals from secondencoder; comparing the first results and the second results; and if thefirst results do not match with the second results stopping the imagingdevice.
 2. The method according to claim 1 further comprising the steps:reading signals from a third encoder results; comparing the firstresults and the third results; and if the first results do not match thethird results a belt connecting the mandrel to the drum motor is notproperly secured.
 3. The method according to claim according to claim 1wherein slippage of the mandrel and/or vibration of the mandrel duringrotation of the mandrel is indicated when the first results do not matchthe second results.
 4. The method according to claim according to claim1 wherein the mandrel not being secured between the head stock and thetail stock is indicated when the first results do not match the secondresults.